Low-moisture, reduced fat, lipid-based fillings

ABSTRACT

Reduced-fat, low-moisture lipid-based fillings. The lipid-based fillings can be used in a variety of food products. The low moisture, reduced fat, lipid-based filling comprises at least about 20% non-digestible lipid and other suitable optional ingredients. The filling has a water activity of less than about 0.6 and has at least about 20% less digestible fat than a comparable full-fat lipid-based filling. In one embodiment, the filling is a cheese filling. The low moisture, reduced fat, lipid-based cheese filling comprises: (a) from about 20% to about 60% non-digestible lipid; (b) from about 20% to about 75% dehydrated cheese powder; and (c) from about 0% to about 55% bulking agent. The fillings can be used with any suitable substrate to form a food product.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. ProvisionalApplication Serial No. 60/242,608, filed Oct. 23, 2000, which is hereinincorporated by reference.

TECHNICAL FIELD

The present invention relates to lipid-based fillings. Morespecifically, it relates to lipid-based fillings that have reduced fatand low moisture.

BACKGROUND OF THE INVENTION

Lipid-based fillings are used to produce a variety of food items. Forinstance, sandwich cookies and crackers are very popular food items inwhich lipid-based fillings are used. Typically, two identical biscuits(the shells or basecakes) contain a layer of sweet or savory fatlipid-based filling. There are many variations on this basic type. Forexample, the shells may be dissimilar in shape or color and one shellmay have a hole or holes through which the lipid-based filling can beseen. The sandwich may be formed with wafer sheets and have multiplelayers of lipid-based filling between the wafers. Lipid-based fillingsandwich biscuits may be enrobed with a chocolate or other coating.

The control of water activity (Aw) in a food product can enable the foodproduct to resist spoilage and maintain a fresh taste and mouthfeel. Thewater activity of a food, or a food subsystem thereof, is a usefulmeasurement of the degree of “freeness” of water contained in the food.The relatively high water activities that are associated with manylipid-based fillings made by standard formulations permit microbialgrowth, moisture migration, and other problems to occur in the foodproduct. Fillings with high water activities are, essentially, a mediumfor supporting microbial growth and, therefore, have limited shelflives. In addition, fillings with high water activities generally allowwater to migrate into the surrounding foodstuff. When the surroundingfoodstuff is a material of significantly lower water activity, such as abaked dough, the migration of moisture into the baked dough can make thebaked dough “soggy.”

In Western countries, there is a general trend away from foods that arehigh in fat and calories, and decreasing dietary fats has been ofspecial interest since fats have a significantly higher caloric densitythan either carbohydrates or protein. Hence, consumers have increasinglydemanded food products with decreased caloric intake from fats.

Accordingly, it would be desirable to provide lipid-based fillingshaving reduced fat and low moisture.

SUMMARY OF THE INVENTION

The present invention provides reduced-fat, low-moisture lipid-basedfillings. The lipid-based fillings can be used in a variety of foodproducts. The low moisture, reduced fat, lipid-based filling comprisesat least about 20% non-digestible lipid and other suitable optionalingredients. The filling has a water activity of less than about 0.6 andhas at least about 20% less digestible fat than a comparable full-fatlipid-based filling.

In one embodiment, the filling is a cheese filling. The low moisture,reduced fat, lipid-based cheese filling comprises:

(a) from about 20% to about 60% non-digestible lipid;

(b) from about 20% to about 75% dehydrated cheese powder; and

(c) from about 0% to about 55% bulking agent.

Although not as preferred, in an alternate embodiment, the fillingcomprises at least about 20% lipid, wherein said lipid comprises: (1)from about 20% to about 100% non-digestible lipid; and (2) from about 0%to about 80% digestible lipid. In one alternate embodiment, the fillingis a cheese filling comprising:

(a) at least 20% lipid, wherein said lipid comprises:

(1) from about 20% to about 100% non-digestible lipid; and

(2) from about 0% to about 80% digestible lipid;

(b) from about 20% to about 75% dehydrated cheese powder; and

(c) from about 0% to about 55% bulking agent.

The fillings of the present invention can be used with any suitablesubstrate to form a food product; alternatively the fillings can be usedas a stand-alone food item.

DETAILED DESCRIPTION

A. Definitions

As used herein, “lipid-based filling” includes any filling comprising atleast about 20% lipid.

As used herein, “reduced fat” means at least about 20% less digestiblefat than a comparable full-fat lipid-based filling.

As used herein, “low moisture” means a water activity of less than about0.6.

As used herein, “added lipid” refers to lipid which is added over andabove that amount inherently present in the other ingredients.

As used herein, the term “lipid” refers to edible fatty substances in ageneral sense, including natural or synthetic fats and oils consistingessentially of triglycerides, such as, for example soybean oil, cornoil, cottonseed oil, sunflower oil, palm oil, coconut oil, canola oil,fish oil, lard and tallow, which may have been partially or completelyhydrogenated or modified otherwise, as well as non-toxic fatty materialshaving properties similar to triglycerides, herein referred to asnon-digestible fats, which materials may be partially or fullyindigestible. Reduced calorie fats and edible non-digestible fats, oilsor fat substitutes are also included in the term. Mixed triglyceridesmade from medium and long chain saturated and/or unsaturated fatty acidsare also included in the term. See, for example, U.S. Pat. No. 5,288,512to Seiden. Oils that contain medium chain triglycerides can also beused. See, e.g., U.S. Pat. No. 4,863,753 to Hunter et al. Other oilswhich may be used include a triacylglycerol oil such as liquid Salatrim™oil (sold under the trade name Benefat™ III by Cultor Food Science, NewYork, N.Y.).

The term “non-digestible fat” refers to those edible fatty materialsthat are partially or totally indigestible, e.g., polyol fatty acidpolyesters, such as OLEAN™.

While this invention will be generally described in terms of Olestra, itshould be readily apparent that other fat substitutes or mixturesthereof could also be utilized in, and are contemplated by, thisinvention. Mixtures of fats and fat substitutes are also contemplatedherein.

By “polyol” is meant a polyhydric alcohol containing at least 4,preferably from 4 to 11 hydroxyl groups. Polyols include sugars (i.e.,monosaccharides, disaccharides, and trisaccharides), sugar alcohols,other sugar derivatives (i.e., alkyl glucosides), polyglycerols such asdiglycerol and triglycerol, pentaerythritol, sugar ethers such assorbitan and polyvinyl alcohols. Specific examples of suitable sugars,sugar alcohols and sugar derivatives include xylose, arabinose, ribose,xylitol, erythritol, glucose, methyl glucoside, mannose, galactose,fructose, sorbitol, maltose, lactose, sucrose, raffinose, andmaltotriose.

By “polyol fatty acid polyester” is meant a polyol having at least 4fatty acid ester groups. Polyol fatty acid esters that contain 3 or lessfatty acid ester groups are generally digested in, and the products ofdigestion are absorbed from, the intestinal tract much in the manner ofordinary triglyceride fats or oils, whereas those polyol fatty acidesters containing 4 or more fatty acid ester groups are substantiallynon-digestible and consequently non-absorbable by the human body. It isnot necessary that all of the hydroxyl groups of the polyol beesterified, but it is preferable that disaccharide molecules contain nomore than 3 unesterified hydroxyl groups for the purpose of beingnon-digestible. Typically, substantially all, e.g., at least about 85%,of the hydroxyl groups of the polyol are esterified. In the case ofsucrose polyesters, typically from about 7 to 8 of the hydroxyl groupsof the polyol are esterified.

The polyol fatty acid esters typically contain fatty acid radicalstypically having at least 4 carbon atoms and up to 26 carbon atoms.These fatty acid radicals can be derived from naturally occurring orsynthetic fatty acids. The fatty acid radicals can be saturated orunsaturated, including positional or geometric isomers, e.g., cis- ortrans- isomers, and can be the same for all ester groups, or can bemixtures of different fatty acids.

Liquid non-digestible oils are also included in the term “lipid.” Liquidnon-digestible oils have a complete melting point below about 37° C.include liquid polyol fatty acid polyesters (see Jandacek; U.S. Pat. No.4,005,195; issued Jan. 25, 1977); liquid esters of tricarballylic acids(see Hamm; U.S. Pat. No. 4,508,746; issued Apr. 2, 1985); liquiddiesters of dicarboxylic acids such as derivatives of malonic andsuccinic acid (see Fulcher; U.S. Pat. No. 4,582,927; issued Apr. 15,1986); liquid triglycerides of alpha-branched chain carboxylic acids(see Whyte; U.S. Pat. No. 3,579,548; issued May 18, 1971); liquid ethersand ether esters containing the neopentyl moiety (see Minich; U.S. Pat.No. 2,962,419; issued Nov. 29, 1960); liquid fatty polyethers ofpolyglycerol (See Hunter et al; U.S. Pat. No. 3,932,532; issued Jan. 13,1976); liquid alkyl glycoside fatty acid polyesters (see Meyer et al;U.S. Pat. No. 4,840,815; issued Jun. 20, 1989); liquid polyesters of twoether linked hydroxypolycarboxylic acids (e.g., citric or isocitricacid) (see Huhn et al; U.S. Pat. No. 4,888,195; issued Dec. 19, 1988);various liquid esterfied alkoxylated polyols including liquid esters ofepoxide-extended polyols such as liquid esterified propoxylatedglycerins (see White et al; U.S. Pat. No. 4,861,613; issued Aug. 29,1989; Cooper et al; U.S. Pat. No. 5,399,729; issued Mar. 21, 1995;Mazurek; U.S. Pat. No. 5,589,217; issued Dec. 31, 1996; and Mazurek;U.S. Pat. No. 5,597,605; issued Jan. 28, 1997); liquid esterifiedethoxylated sugar and sugar alcohol esters (see Ennis et al; U.S. Pat.No. 5,077,073); liquid esterified ethoxylated alkyl glycosides (seeEnnis et al; U.S. Pat. No. 5,059,443, issued Oct. 22, 1991); liquidesterified alkoxylated polysaccharides (see Cooper; U.S. Pat. No.5,273,772; issued Dec. 28, 1993); liquid linked esterified alkoxylatedpolyols (see Ferenz; U.S. Pat. No. 5,427,815; issued Jun. 27, 1995 andFerenz et al; U.S. Pat. No. 5,374,446; issued Dec. 20, 1994); liquidesterfied polyoxyalkylene block copolymers (see Cooper; U.S. Pat. No.5,308,634; issued May 3, 1994); liquid esterified polyethers containingring-opened oxolane units (see Cooper; U.S. Pat. No. 5,389,392; issuedFeb. 14, 1995); liquid alkoxylated polyglycerol polyesters (see Harris;U.S. Pat. No. 5,399,371; issued Mar. 21, 1995); liquid partiallyesterified polysaccharides (see White; U.S. Pat. No. 4,959,466; issuedSep. 25, 1990); as well as liquid polydimethyl siloxanes (e.g., FluidSilicones available from Dow Corning). All of the foregoing patentsrelating to the liquid nondigestible oil component are incorporatedherein by reference. Solid non-digestible fats or other solid materialscan be added to the liquid non-digestible oils to prevent passive oilloss. Particularly preferred non-digestible fat compositions includethose described in U.S. Pat. No. 5,490,995 issued to Corrigan, 1996,U.S. Pat. No. 5,480,667 issued to Corrigan et al, 1996, U.S. Pat. No.5,451,416 issued to Johnston et al, 1995 and U.S. Pat. No. 5,422,131issued to Elsen et al, 1995. U.S. Pat. No. 5,419,925 issued to Seiden etal, 1995 describes mixtures of reduced calorie triglycerides and polyolpolyesters that can be used herein but provides more digestible fat thanis typically preferred.

The preferred non-digestible fats are fatty materials having propertiessimilar to triglycerides such as sucrose polyesters. OLEAN™, a preferrednon-digestible fat, is made by The Procter and Gamble Company. Thesepreferred non-digestible fat are described in Young; et al., U.S. Pat.No. 5,085,884, issued Feb. 4, 1992, and U.S. Pat. No. 5,422,131, issuedJun. 6, 1995 to Elsen et al.

All percentages are by weight unless otherwise specified.

B. Lipid-Based Filling

As used herein, “lipid-based filling” includes any filling comprising atleast about 20% lipid. Preferably, the principal lipid component is anon-digestible fat. The fillings of this invention typically have alipid component making up from about 20% to about 60% of the totalfilling composition. The preferred fillings are of a low moisturecontent to promote shelf stability. The lipid-based fillings have awater activity (Aw) of less than about 0.6.

The inclusion of a sucrose polyester non-digestible fat allows for areduced fat, reduced calorie product that has improved mouthfeel andflavor versus other lowfat filled biscuits. In comparison, many lowfatfilled biscuits use high levels of polyols, emulsifiers, fillers, ormoisture to achieve fat reduction. High moisture contributes tomicrobial growth, and polyols, emulsifiers, and fillers can contributecalories and limit consistency, mouthfeel, and flavor.

Additionally, the filling may comprise additional, optional components.

Optional Ingredients

The filling can contain other suitable ingredients depending upon theflavor or other properties desired. As used herein, “optionalingredients” refers to one or a mixture of more than one of these othersuitable ingredients. Non-limiting examples of suitable optionalingredients are set forth below.

The lipid-based fillings of this invention can contain a flavoring and,in most embodiments, at least one other component in addition to theflavoring and the fat components. For example, sandwich cracker fillerstypically contain salt. Sandwich cookie fillers typically contain asweetener; indeed, in sweet creams, the major ingredients are sweetenerand fat. The sweetener can be a natural sweetener such as sugar,primarily sucrose, glucose, fructose, and maltose, or any one of knownartificial sweeteners including 1-aspartyl-1-phenylalanine methyl ester(commercially available as aspartame or Nutri-Sweet ™), saccharine,cyclamate and the potassium salt of6-methyl-3,4-dihydro-1,2,3-oxathiazin-4-one-2,2-dioxide (commerciallyavailable as acesulfame-K), or a mixture of these.

The filling compositions of the present invention can also contain otheringredients depending upon the flavor or other properties desired. Forinstance, milk or milk powders or solids (preferably nonfat) can beincluded, as can eggs, gelatin, cornstarch or other starch such aspotato or rice, fruits and nuts, vegetable, cheese and meat pieces,colorings, and lecithin or other emulsifiers. Compositions containingartificial sweeteners substantially sweeter than sucrose typicallycontain a bulking agent such as polydextrose, isomalt, isomaltulose,polyglucose, polymaltose, carboxymethyl-cellulose, microcrystallinecellulose, cellulose gel, arabinogalactan, as well as mixtures orcombinations of any of these. These agents can be included in amountsreadily determinable by the skilled artisan.

An emulsifier can be used in the present invention. The emulsifier canbe any food compatible emulsifier such as mono- and di-glycerides,lecithin, sucrose monoesters, polyglycerol esters (“PGE”), sorbitanesters, polyethoxylated glycerols, and mixtures thereof. Typically, upto about 3%, preferably from about 1% to about 3%, stabilizer oremulsifier can be used.

The filling compositions can also optionally comprise flavorants.“Flavorants,” as the term is used herein, are agents which contribute toor enhance the flavor of the nut butter. These include sweeteners,flavor enhancers, artificial sweeteners, natural and artificial flavors,flavored or candied bits, nut chunks and other additives whichcontribute to the flavor of the filling. Sweeteners are selected fromthe group consisting of sugars, sugar mixtures, artificial sweetenersand other naturally sweet materials. Sugars include, for example,sucrose, fructose, dextrose, honey, molasses, high fructose corn syrup,lactose, maltose, and maltose syrups. Preferably, the sweetener will besomething which has a sweetness intensity about that of sucrose orfructose. Sweeteners can be added at a level of about 5% to about 20%,preferably from about 7% to about 12%.

Artificial sweeteners such as aspartame, acesulfam, saccharine,cyclamate, and glycyrrhizin can also be used. The amount of artificialsweetener used should be that amount effective to produce the sweetnessthat is desired, and would be about the equivalent of the addition offrom about 1% to about 7% of sucrose.

Flavor enhancers including salt, or salt substitutes such as potassiumchloride, sodium chloride/potassium chloride mixtures, and seasonedsalts can also be used. The level of flavor enhancer used is a matter ofthe desired taste level, but usually is from about 0.1% to about 2%.Other flavorants include natural or artificial flavors, roasted flavors,and praline/caramel flavors, walnut flavors, almond flavors, and flavorcompositions.

The present invention can also employ nut chunks and other flavoredadditives which can be mixed with the filling. These additives includechocolate chips or bits or other flavored bits (e.g., butterscotch andpeanuts), jellies (either low calorie jellies or regular jelly orpreserves), and praline nuts or other candies. These additives areusually added at a level of from about 1% to about 20% by weight. Nutchunks and flavored bits can contain fats and oils. Thus, the additionof these materials can affect the fat content and the calorie level ofthe nut spread.

A bulking agent can be included in the cheese filling composition.Bulking agents typically add body or texture to the filling and can benon-nutritive or low calorie materials. Suitable bulking agents includehydrolyzed starch (e.g., corn syrup solids or maltodextrin), dextrose,polydextrose, mono- and disaccharides, starches (e.g., corn, potato,tapioca wheat), as well as mixtures thereof. Corn syrup solids,polydextrose (such as that available from Pfizer Chemicals) andmaltodextrin are preferred bulking agents. Sugar substitutes whichfunction like sugars but which are non-nutritive can also be used. Suchsugar substitutes include the 5-C-hydroxyalkylaldohexoses described inU.S. Pat. No. 5,041,541, issued Aug. 20, 1991 to Mazur.

The filling can also be fortified with vitamins and/or minerals. Thesecan include, but are not limited to, Vitamin A, Vitamin D, Vitamin K,Vitamin C, Vitamin E, thiamin, riboflavin, niacin, Vitamin B-6, VitaminB-12, biotin, pantothenic acid, iron, calcium, niacin, magnesium, andmixtures thereof.

Sterols or sterol esters can also be incorporated into the filling ofthe present invention. Suitable sterol and sterol ester compositions aredescribed in U.S. Pat. No. 3,751,569, issued Aug. 7, 1973 to Erickson;U.S. Pat. No. 5,244,887, issued Sep. 14, 1993 to Straub; U.S. Pat. No.3,865,939 issued Feb. 11, 1975 to Jandacek et al.; U.S. Pat. No.3,085,939, issued Apr. 16, 1963 to Wruble; U.S. Pat. No. 5,502,045,issued Mar. 26, 1996 to Miettinen; U.S. Pat. No. 5,958,913, issued Sep.28, 1999 to Miettinen; and in co-pending P&G Application 8003P, filedMar. 27, 2000.

C. Cheese Filling

A preferred filling of the present invention is a cheese fillingcomprising from about 20% to about 60%, preferably from about 25% toabout 35%, and most preferably from about 28% to about 33%,non-digestible lipid; and from about 20% to about 75%, preferably fromabout 40% to about 60%, and most preferably from about 45% to about 55%,dehydrated cheese powder; and from about 0% to about 55%, preferablyfrom about 5% to about 20%, and most preferably from about 10% to about15% bulking agent.

The preferred cheese filling is reduced in fat and has a low moisturecontent.

Dehydrated Cheese Powder

Any dehydrated cheese powder suitable for producing an instant cheese,such as those disclosed in U.S. Pat. No. 5,935,633, issued Aug. 10, 1999to Derian, can be used to make the preferred cheese filling of thepresent invention. The dehydrated cheese powders generally have lessthan about 3.5% of moisture.

Dehydrated cheese powders which may be employed in the instant cheesecompositions of the present invention include, but are not limited to,Anejo Enchilado Cheese Powder 73870, Monterey Jack Cheese Powder 9497,Mozzarella Zing Cheese Powder 9498, Swiss Zing Cheese Powder 9481,Cotija Cheese Powder 73401, Parmtang Cheese Powder 9335, Romano TangCheese Powder 9381, Sharpee for Baking Cheese Powder 9510, Panela CheesePowder 73397, Hexagon Cheese Powder 9483, Cotija with Jalapeno CheesePowder 73857 and Cuatro Queso Cheese Powder 73856. Especially preferredis Cheez Zing.

The cheese powders and numbers described above are the commercial namesfor cheese powders made by Kraft Food Ingredients, a division of KraftFoods, Inc.

A single dehydrated cheese powder or a mixture of more than one cheesepowder may be used as the dehydrated cheese powder in the cheese fillingcompositions of the present invention.

Bulking Agent

A bulking agent can be included in the cheese filling composition.Bulking agents typically add body or texture to the filling and can benon-nutritive or low calorie materials. Suitable bulking agents includehydrolyzed starch (e.g., corn syrup solids or maltodextrin), dextrose,polydextrose, mono- and disaccharides, starches (e.g., corn, potato,tapioca wheat), as well as mixtures thereof. Corn syrup solids,polydextrose (such as that available from Pfizer Chemicals) andmaltodextrin are preferred bulking agents. Sugar substitutes whichfunction like sugars but which are non-nutritive can also be used. Suchsugar substitutes include the 5-C-hydroxyalkylaldohexoses described inU.S. Pat. No. 5,041,541, issued Aug. 20, 1991 to Mazur.

The preferred bulking agent is hydrolyzed starch. The preferredhydrolyzed starches include maltodextrins and corn syrup solids. Thepreferred hydrolyzed starches have Dextrose Equivalent (D.E.) values offrom about 5 to about 30, preferably from about 10 to about 20. Maltrin™M050, M100, M150, M180, M200, and M250 (available from Grain ProcessingCorporation, Iowa) are preferred maltodextrins. The D.E. value is ameasure of the reducing equivalence of the hydrolyzed starch referencedto dextrose and is expressed as a percentage (on a dry basis). Thehigher the D.E. value, the higher the dextrose equivalence of thestarch.

Process for Making Cheese Filling

The dry ingredients are first blended in a suitable mixer, such as aribbon blender. The non-digestible lipid is melted and then combinedwith the dry ingredients. Mixing is continued until the lipid ishomogeneously blended with the dry ingredients.

D. Substrate

Although the present invention is generally described herein in terms ofa lipid-based filling suitable for use in combination with a substrate,it should be understood that the lipid-based filling can also be used asa stand-alone food item. For example, the lipid-based filling can beconsumed without being employed as part of another food item. It isfully contemplated that the lipid-based filling can be separatelypackaged for later consumption or use, such as in a pressurizedcontainer, a bowl, a tub, a jar, or any other suitable container.Furthermore, the lipid-based filling can be used for any otherappropriate uses such as a topping or a spread. For instance, it can bespread on a cracker or toast points and used as an hors d'oeuvre.

The filling of the present invention can be utilized with any suitablesubstrate. For example, the fillings of this invention can be employedin a variety of food products, including bakery, dessert, snack, candy,dairy, nut, meat, egg, and vegetable products. The fillings areespecially adapted to all types of bakery products including leavenedbaked products, both yeast raised and chemically leavened, andunleavened baked products. Bakery products include cakes, breads, rolls,pastries, cookies, biscuits, and savory crackers. Other suitable foodproducts include jelly rolls, pirouettes, wafers, and hollow snackfoods. For example, the filling of the present invention can be used insnack foods such as tortilla sandwiches or potato crisp sandwiches,comprising two chips which sandwich a filling.

Preferred substrates for use herein include base cakes such as crackers,cookies, and biscuits; these can be used with the filling of the presentinvention to form sandwich biscuits. (As used herein, the term “sandwichbiscuits” is broad enough to include sandwich cookies, sandwichcrackers, and the like.) Any suitable base cake can be used for makingthe sandwich biscuits of the present invention. Preferably, the basecake is prepared using non-digestible fat and is low in fat andcalories.

The preparation of a preferred sandwich biscuit is described below.

E. Sandwich Biscuit

For sandwich biscuits, the fillings are formulated, mixed, andoptionally aerated before applying to the shell or basecake bystencilling, depositing, extruding, or other means known to the skilledartisan. The basecake and filler combination is then capped with anotherbasecake.

F. Alternate Embodiment

Although not as preferred, in an alternate embodiment, the fillingcomprises at least about 20% lipid, wherein said lipid comprises: (1)from about 20% to about 100% non-digestible lipid; and (2) from about 0%to about 80% digestible lipid. In one embodiment, the filling is acheese filling comprising:

(a) at least 20% lipid, wherein said lipid comprises:

(1) from about 20% to about 100% non-digestible lipid; and

(2) from about 0% to about 80% digestible lipid;

(b) from about 20% to about 75% dehydrated cheese powder; and

(c) from about 0% to about 55% bulking agent.

ANALYTICAL METHODS

Parameters used to characterize elements of the present invention arequantified by particular analytical methods. These methods are describedin detail as follows. (All laboratory instruments should be operatedaccording to manufacturers' instructions, as set forth in the instrumentoperation manuals and/or other instructional materials, unless otherwiseindicated.)

1. Fat Content

The method used to measure total fat content (both digestible andnon-digestible) herein is AOAC 935.39 (1997).

Digestible Fat Content

Digestible lipid (NLEA) method AOAC PVM 4:1995 is used to determine thedigestible fat content.

Non-Digestible Fat Content

Non-Digestible Fat Content=Total Fat Content−Digestible Fat Content

Olestra-Containing Foods—Digestible Fat and Saturated Fat: The contentof total digestible fat and total digestible saturated fat of a food ismeasured according to the published AOAC peer-verified method forquantifying fat in olestra-containing snack foods (AOAC Peer-VerifiedMethod PVM 4:1995, “Capillary Gas Chromatographic Determination of Fatin Olestra Savory Snack Products”, AOAC International, Gaithersburg,Md.).

2. Moisture Content

The moisture content can be determined by a forced air oven volatilesmethod as follows:

Equipment:

Forced air oven, aluminum tins with lids, Cabinet-type desiccator

Procedure:

1. Weigh tin and lid to 0.0001 grams and record weight as tare weight

2. Place 2-3 gram ground sample into tin, weigh to 0.0001 grams andrecord as gross weight

3. Set oven temperature to 105° C.

4. Place tin containing the sample in oven for 1 hour, uncovered

5. Remove tin containing the sample from the oven, cover the tin, andplace in desiccator until cooled to room temperature

6. Weigh tin, lid and dried sample to 0.0001 grams and record as finaldried weight

Calculations

1. Sample weight=gross wt.−tare wt.

2. Final weight=weight recorded in step 6

3. Moisture Content (%)=[(gross wt−final wt.)/sample wt]×100.

3. Water Activity (Aw)

The water activity is defined as the ratio A_(w)=p/p_(o) where prepresents the actual partial pressure of water vapor and p_(o) themaximum possible water vapor pressure of pure water (saturationpressure) at the same temperature. The A_(w) level is thereforedimensionless; pure water has a level of 1.0, and a completelywater-free substance has a level of 0.0. The relationship between theequilibrium relative humidity ERH in a food and the water activity isA_(w)×100=ERH.

Instrument

Conductivity humidity meter Rotronic Hygroskop DT (model WA-40 TH) withan operational temperature range from 0 to 100° C., and 0 to 100% RH.

Method

1. Weigh˜5 grams of the sample and transfer it into a plastic bag.

2. Break the sample into small pieces with a flat object.

3. The samples to be measured are placed in small polysterene dishes inthe bottom half of the measuring station.

4. Maintain the temperature constant by setting the equipment in aconstant room temperature, or by using a water bath connected to thecells.

5. Wait until the reading of Aw does not change anymore (reading isstable). A red light from the panel will indicate that the instrument isstill reading a decrease or increase in value for Aw.

6. Remove the dish with the sample from the chamber and measure moisturecontent.

EXAMPLES

The following examples are illustrative of the present invention but arenot meant to be limiting thereof.

Example 1

Sandwich crackers made with a reduced fat filling are prepared asfollows:

Base Cake Formulation Ingredient % 62DE Corn Syrup (Quality IngredientsCorp., Chester, N.J.) 2.00 Olean ® (Procter & Gamble Co., Cincinnati,OH.) 12.37 Hot water 8.61 enzyme tabs 1 tab L-Cysteine HCl Monohydrate(Quality Ingredients Corp., Chester 0.05 N.J.) Granulated Sugar (HollySugar Co., Worland, WY.) 6.02 Salt - TFC Purex (Morton International,Inc., Philadelphia, PA.) 0.32 Flour - soft wheat (Siemer Milling Co.,Teutopolis, IL.) 62.94 Sodium Bicarbonate (Church & Dwight Co.,Princeton, NJ.) 1.34 Calcium Phosphate Monobasic (Regent 12XX, Rhodia,0.54 Cranbury, N.J.) Sodium Aluminum Phosphate (Levair, Rhodia,Cranbury, N.J.) 0.54 Ammonium Bicarbonate (Church & Dwight Co.,Princeton, NJ.) 2.69 Cold water 2.58

Base Cake Making

Dough Making

1. Corn syrup, Olean, hot water (160° F.), L-cysteine and enzyme tabletsdissolved in water are weighed into a mixer (APV 100# single bladehorizontal mixer) and then mixed for 30 seconds @ 38 rpm.

2. Next, sugar and salt are weighed into the mixer and then mixed for 2minutes @ 38 rpm.

3. Then the remaining dry ingredients (flour, sodium bicarbonate, andnon-ammonia leavening salts) are weighed into mixer and mixed for 3minutes at 45 rpm.

4. Then ammonium bicarbonate, dissolved in cool water, is added andmixed for one minute @ 60 rpm.

5. The resulting dough is emptied into a stainless steel tram, coveredwith plastic sheet, and allowed to “rest” at room temperature for 30minutes.

Dough Forming

1. Dough is fed through a three-roll mill (Two initial corrugated rolldiameters=16.5″, and one smooth roll diameter=11.8″) and sheeted to0.25″. The take-off belt speed exiting the three-roll mill is 2.0 fpm,and is matched to the speed of the dough sheet as it exits the threeroll mill.

2. The sheet is sent through a calender roll #1 (a 11.8″dIA. two-rollmill), and sheeted to ˜0.10″. The take-off belt speed exiting thecalender roll #1 is 4.4 fpm, and is matched to the speed of the doughsheet as it exits the calender roll #1.

3. As the sheet came through calender roll #1, it is folded over eighttimes at a width of ˜10″ to form a bundle of laminated dough. The bundleis covered with plastic film to prevent dehydration and briefly setaside while additional bundles are collected.

4. The laminated sheet of 3 above is sent through the two-roll mill #1again to form 0.10″ sheet.

5. The sheet continued on calender roll #2 to form a finished doughsheet of (˜0.08″) thickness. The take-off belt speed exiting thecalender roll #2 is 7.9 fpm, and is matched to the speed of the doughsheet as it exits the calender roll #2.

6. The dough sheet is then passed under a cutter die roll to formcrackers of approximately 1.1 inch by 1.1 inch square. The belt speed is7.7 fpm. The 3.875″ diameter cutter roll can be designed to cut avariety of shapes. The shape used in this example contains dockingholes. The function of the docking pins is thought to join the doughlayers together and create venting during baking. The roll is obtainedfrom Weidenmiller Colo. (Itasca, Ill.).

7. After separating the web (the portion of the sheet left over afterthe shapes are cut out), the crackers are salted using a roller-salteror equivalent. The web may be recycled back to the dough awaitingintroduction into the three-roll mill.

8. The cracker dough forms are then sprayed with a water mist (flowrate=65-212 g/mIN.) before baking. This helped attain a lighter colorafter baking.

Baking

1. The cracker dough forms are transferred as a continuous feed from thedough forming belt onto the oven band such that their relative spacingis undisturbed (a slight speed differential is permissible if it isdesired to place the cracker dough forms closer, or further apart on theoven band prior to baking). The oven band is made of metal of the openweave versus solid surface type. Solid surface metal oven bands may alsobe used for certain applications.

2. The cracker dough forms are baked in an APV 45 foot long three-zoneindirect-fired oven. Each zone had independent top and bottom heatapplied. Dampers and temperatures in each zone are set at the followingconditions:

1^(st) zone top: 465° F., bottom: 500° F., damper closed

2^(nd) zone top: 480° F., bottom: 520° F., damper ½

3^(rd) zone top: 355° F., bottom: 425° F., damper open

Oven band speed (fpm):13

Final moisture contents are about 0-4%.

Post Baking

1. As hot baked crackers exits the oven, they are sprayed with hot oilor Olean® (˜160° F.) to a level of about 10% their post baked weight.The crackers are passed under heat lamps for ˜15 seconds to aid inabsorption of oil.

2. The crackers are then passed through a cooling tunnel at roomtemperature. Olean® containing products must cool through thetemperature range of 130° F.-140° F. in about 10 minutes to ensure theproper crystalline structure.

Reduced Fat, Low Moisture, Lipid Based Filling Formulation Ingredient %Olestra (Procter and Gamble, Cincinnati, OH) 34.6 American cheese powder(Kraft Food Ingredients, Memphis, TN) 46.5 Cheddar cheese powder (KraftFood Ingredients, Memphis, TN) 4.6 Corn syrup solids (Cargill Company)14.1 Vitamin ADK (BASF) 0.2

Reduced Fat Lipid Based Filling Making

1. The cheese powder, corn syrup solids, and vitamin are weighedtogether and blended in a Hobart (model A-200) mixer for 3 minutes atspeed setting #3.

2. Next, the Olean® is weighed into a container.

3. The Olean® is melted by heating until the temperature reaches 159-162F. For lab scale, can be accomplished on a hot plate.

4. The melted Olean is added slowly to the dry mix from step 1 abovewhile the Hobart is mixing on speed #3. Mixing is continued for 4minutes at speed #3.

5. The mixture is cooled through the temperature range of 130° F.-140°F. in less than about 10 minutes to ensure the proper crystallizingstructure. This can usually be accomplished by ambient cooling for labbatch sizes.

6. The resulting filling is stored or used immediately to preparesandwich crackers.

Preparation of Sandwich Crackers

1. 1.4-1.6 grams of cheese filling prepared above can be applied to thebottom side of a base cake prepared above. For small quantities, thefilling can be applied via a spatula in the lab. For pilot scalequantities, the filling can be dosed into 1.5 gram portions using aRheon Extruder, Model #KN170, onto the base cake. In either case, thefilling can be applied to the base cake at ambient temperature.

2. The top base cake can then be applied with enough pressure so thatthe filling flows out to meet the edge of the base cake.

3. Steps 1 and 2 can be repeated for the desired number of sandwichcrackers.

INCORPORATION BY REFERENCE

All of the aforementioned patents, publications, and other referencesare herein incorporated by reference in their entirety.

Also incorporated herein by reference are U.S. Provisional Applications60/242,609 (“Reduced Fat Lipid-Based Fillings,” Trout et al.),60/242,607 (“Reduced Saturated Fat Lipid-Based Fillings,” Trout et al.),60/242,460 (“Filled Snacks,” Heisey et al.), and 60/242,606 (“Low FatNut Spread Composition and Process for Making the Same,” Wong et al.),all filed Oct. 23, 2000.

What is claimed:
 1. A low moisture, reduced fat, lipid-based cheesefilling comprising: (a) from about 20% to about 60% non-digestiblelipid; (b) from about 20% to about 75% dehydrated cheese powder, and (c)from about 0% to about 55% bulking agent; wherein said filling has awater activity of less than about 0.6.
 2. A low moisture, reduced fat,lipid-based cheese filling comprising: (a) at least 20% lipid, whereinsaid lipid comprises: (1) from about 20% to about 100% non-digestiblelipid; and (2) from about 0% to about 80% digestible lipid; (b) fromabout 20% to about 75% dehydrated cheese powder; and (c) from about 0%to about 55% bulking agent.